Process for producing a reinforcing woven fabric, a preform and a fiber reinforced plastic molded component

ABSTRACT

A process for producing a reinforcing woven fabric includes sticking a resin material on at least one surface of a fabric substrate including a plurality of reinforcing fiber bundles and varying the relative position of a plurality of reinforcing fiber bundles to peel the resin material stuck over two or more reinforcing fiber bundles from a part of the two or more reinforcing fiber bundles.

RELATED APPLICATIONS

This is a divisional of U.S. Ser. No. 11/989,258, filed Feb. 12, 2008,which is a §371 of International Application No. PCT/JP2006/307810, withan international filing date of Apr. 13, 2006 (WO 2007/013204 A1,published Feb. 1, 2007), which is based on Japanese Patent ApplicationNo. 2005-220187, filed Jul. 29, 2005.

TECHNICAL FIELD

This disclosure relates to a reinforcing woven fabric which is good indeformability and easy to shape into a three-dimensional shape, and alsohas an excellent handling property and shape retention upon shaping intoa three-dimensional shape, a preform using it, a fiber reinforcedplastic molded component, and a process for producing them.

BACKGROUND

A fiber reinforced plastic molded component composed of a continuousreinforcing fiber such as a carbon fiber, glass fiber and aramid fiber,and a cured material of a matrix resin such as an epoxy resin,unsaturated polyester resin, vinyl ester resin and phenol resin showsexcellent mechanical properties of strength, elastic modulus, impactresistance and fatigue resistance, and also has a characteristic ofbeing light in weight, so that it is widely used in applications such asaviation, space, sport, automobile, marine vessel, home electricappliance, civil engineering and construction.

In production of the fiber reinforced plastic molded component, there isoften used a method where a prepreg, a sheet-like intermediate materialin which an uncured thermosetting resin is impregnated in a fabricsubstrate constituted by a continuous reinforced fiber, is laid up on amolding tool, then pressurized/heated in an autoclave. However, theuncured thermosetting resin impregnated in a prepreg has generally ahigh viscosity, and the relative position of reinforcing fiber bundlesconstituting a fabric substrate is constrained by the resin impregnated.Therefore, the prepreg has a high rigidity and low deformability, bad infollowing a mold and difficult to shape into a three-dimensional shape.This is one cause for hamper of production improvement.

To the above-described problem, an infusing molding method has recentlybeen paid attentions as a method for improving productivity, which istypified by RTM (Resin Transfer Molding) where a reinforcing fibersubstrate that a matrix resin is not impregnated in beforehand(so-called dry) is positioned inside a molding tool, then, by infusing aliquid matrix resin with low viscosity, the matrix resin is impregnatedin the reinforcing fiber substrate, and cured after that.

In the infusing molding method, generally, it takes procedures where adry reinforcing fiber substrate that a matrix resin is not impregnatedin is laid up on a molding tool so that it follows a shape of mold,which is next covered by a vacuum bagging film or a molding tool, then,a resin is infused therein and cured. Since a dry reinforcing fibersubstrate is used in this method, deformability is large and it followswell a three-dimensional shape. However, on the other hand, there is aproblem that shape retention is bad, laying-up operations take time,occupying an expensive molding tool for a long time.

To more improve productivity beyond the above-described problems, thereis also proposed a method that a laying-up process of reinforcing fibersubstrates and an infusion process of resin are separated. Namely,first, it is provided with a shape (near-net-shape), i.e., substantiallythe same shape as the case of laying up dry reinforcing fiber substrateson a molding tool, and a so-called preform retaining the shape isformed. Thereafter, the preform is placed on a molding tool, in which amatrix resin is infused rapidly without requiring laying-up andshape-providing operations on the molding tool

Specifically, for example, in U.S. Pat. No. 5,071,711 and JP 4-26180 A,there is proposed a technique that a surface of a reinforcing fibersubstrate is provided with a thermoplastic-like resin or a thermosettingresin, after being laid up in a shaping mold of a given shape, the resinis melt to thermally bond the interlayer of the reinforcing fibersubstrate, cooled and solidified to form a preform retained in a givenshape. According to these proposals, it is possible to obtain a preformexcellent in shape retention by deforming a reinforcing fiber substratein a given shape and bonding the interlayer.

However, according to these methods, there is an adverse effect that bysticking a resin component onto the surface of a reinforcing fibersubstrate before forming a preform, rigidity of the reinforcing fibersubstrate becomes strong, deformability is lowered and a shape-followingproperty is deteriorated. Namely, in the case of trying to be deformedinto a three-dimensional shape, a reinforcing fiber substrate cannotfollow the shape and wrinkle occurs, as a result, the wrinkle of thereinforcing fiber substrate appears on the surface of the moldedcomponent obtained by impregnating and curing a matrix resin, which isinferior in the designing property as a commercial product. Besides,there are problems that impregnation deficiency takes place resultingfrom the wrinkle part occurred in a reinforcing fiber substrate uponinfusing a matrix resin, further, the reinforcing fiber substrate isfolded or broken at the wrinkle part, thereby the mechanical propertiesare deteriorated. This phenomenon is particularly notable in the case ofusing a method that imposes a reinforcing fiber substrate on a shapingmold for providing a shape in order to produce a three-dimensional shapewith a large concavity and convexity.

From these facts, it has been strongly desired to provide a reinforcingfiber substrate having an excellent deformability capable of following acomplicated shape without generating wrinkle in providing a shape aswell as it has an excellent shape retention after providing the shape.

It could therefore be helpful to provide a reinforcing woven fabrichaving an excellent deformability capable of following a complicatedshape and also is excellent in retention of the shape, a preform usingit, a fiber reinforced plastic molded component using it, and a processfor producing them, thereby to improve the productivity of the fiberreinforced plastic molded component.

SUMMARY

We thus provide:

-   -   (1) A reinforcing woven fabric including a resin material stuck        on at least one surface of a fabric substrate containing a        plurality of reinforcing fiber bundles, wherein the maximum        value of load till a tensile strain in a non fiber axial tensile        test reaches 1% is in a range of 0.01 to 0.75 N.    -   (2) The reinforcing woven fabric according to the        above-described (1), wherein the maximum value of load till a        tensile strain in a non fiber axial tensile test reaches 5% is        in a range of 0.1 to 1.0 N.    -   (3) The reinforcing woven fabric according to the        above-described (1) or (2), wherein the stuck amount of the        resin material is 1 to 50 g/m².    -   (4) The reinforcing woven fabric according to any one of the        above-described (1) to (3), wherein the resin material mainly        comprises a thermoplastic resin.    -   (5) The reinforcing woven fabric according to any one of the        above-described (1) to (4), wherein the fabric substrate is a        bidirectional fabric.    -   (6) The reinforcing woven fabric according to any one of the        above-described (1) to (5), wherein the reinforcing fiber bundle        is a carbon fiber bundle.    -   (7) The preform including at least one layer of the reinforcing        woven fabric according to any one of the above-described (1) to        (6).    -   (8) The fiber reinforced plastic molded component, wherein a        matrix resin is impregnated in the preform according to the        above-described (7).    -   (9) A process for producing a reinforcing woven fabric        including: sticking a resin material on at least one surface of        a fabric substrate containing a plurality of reinforcing fiber        bundles; and then varying the relative position of a plurality        of reinforcing fiber bundles constituting the fabric substrate        to peel the resin material stuck over two or more reinforcing        fiber bundles from a part of the two or more reinforcing fiber        bundles.    -   (10) The process for producing a reinforcing woven fabric        according to the above-described (9), wherein by giving the        fabric substrate a shearing deformation of 5 to 45°, the        relative position of a plurality of reinforcing fiber bundles        constituting the fabric substrate is varied.    -   (11) A process for producing a preform including: laying up a        reinforcing woven fabric according to any one of the        above-described (1) to (6) and a fabric substrate containing        reinforcing fiber bundles into a shaping mold; next,        pressurizing and heating the layered product of the reinforcing        woven fabric and the fabric substrate to soften the resin        material stuck on the reinforcing woven fabric and to bond the        interlayer of the layered product.    -   (12) A process for producing a preform including: laying up a        reinforcing woven fabric according to any one of the        above-described (1) to (6) into a shaping mold; and then        pressurizing and heating the layered product of the reinforcing        woven fabric to soften the resin material stuck on the        reinforcing woven fabric and to bond the interlayer of the        layered product.    -   (13) The process for producing a preform, according to the        above-described (11) or (12), including: positioning the layered        product between at least two facing shaping molds; pressurizing        a part of the layered product; and then pressurizing and heating        the remaining part.    -   (14) The process for producing a preform, according to the        above-described (11) or (12), including: pressurizing a part of        a layered product laid up on a shaping mold, then covering a        sheet on the layered product, pressurizing and heating the        layered product via the sheet by gas or liquid.    -   (15) A process for producing a fiber reinforced plastic molded        component, including: impregnating a matrix resin into a preform        produced by the process for producing according to any one of        the above-described (11) to (14), and curing or solidifying the        matrix resin.

A resin material being “stuck” means a state where in a part where asurface of a reinforcing fiber bundle constituting a fabric substratecontacts a resin material, the resin material penetrates between aplurality of single yarns consisting a reinforcing fiber bundle, andthen the reinforcing woven fabric and the resin material are bonded.

The reinforcing woven fabric can be deformed with a good productivityand can retain a shape even if the shape is too complicated to obtainconventionally. Therefore, it is possible to produce a fiber reinforcedplastic molded component excellent in a designing property andmechanical property with a good productivity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan pattern view showing a reinforcing woven fabric thatsticks a resin material on the surface.

FIG. 2 is a sectional pattern view showing a reinforcing woven fabricthat sticks a resin material on the surface.

FIG. 3 is a plan pattern view showing a test piece shape of a non fiberaxis tensile test.

FIG. 4 is a plan pattern view showing a deformed reinforcing wovenfabric by a non fiber axis tensile test.

FIG. 5 is a plan pattern view showing a reinforcing woven fabric on thatsurface a resin material sticks in large amount.

FIG. 6 is a plan pattern view showing a reinforcing woven fabric on thatsurface a resin material sticks.

FIG. 7 is a sectional pattern view showing a reinforcing woven fabric onthat surface a resin material sticks.

FIG. 8 is a plan pattern view showing a reinforcing woven fabric that aresin material sticks only on a part of reinforcing fiber bundle.

FIG. 9 is a sectional pattern view showing a reinforcing woven fabricthat a resin material sticks only on a part of reinforcing fiber bundle.

FIG. 10 is a plan pattern view showing a reinforcing woven fabricprovided with shearing deformation.

FIG. 11 is a side pattern view showing one embodiment of a method fordeforming a layered product into a shape along a shaping mold,pressurizing and heating.

FIG. 12 is a side pattern view showing another embodiment of a methodfor deforming a layered product into a shape along a shaping mold,pressurizing and heating.

FIG. 13 is a side pattern view showing another embodiment of a methodfor deforming a layered product into a shape along a shaping mold,pressurizing and heating.

FIG. 14 is a side pattern view showing another embodiment of a methodfor deforming a layered product into a shape along a shaping mold,pressurizing and heating.

FIG. 15 is a side pattern view showing another embodiment of a methodfor deforming a layered product into a shape along a shaping mold,pressurizing and heating.

FIG. 16 is a schematic perspective view showing one embodiment of amechanism for swinging a fabric substrate in a width direction.

FIG. 17 is a schematic perspective view showing another embodiment of amechanism for swinging a fabric substrate in the width direction.

FIG. 18 is a schematic perspective view showing another embodiment of amechanism for swinging a fabric substrate in the width direction.

FIG. 19 is a schematic perspective view showing another embodiment of amechanism for swinging a fabric substrate in the width direction.

DESCRIPTION OF REFERENCE NUMERALS

-   -   11 resin material stuck over two reinforcing fiber bundles of        fabric substrate    -   12 resin material stuck over three reinforcing fiber bundles of        fabric substrate    -   13 resin material stuck only on one reinforcing fiber bundle of        fabric substrate    -   14 reinforcing fiber bundle constituting fabric substrate (warp)    -   15 reinforcing fiber bundle constituting fabric substrate (weft)    -   31 test piece of fabric substrate    -   41 test piece attaching part    -   42 test piece of fabric substrate    -   51 resin material stuck on the surface of fabric substrate    -   81 resin material stuck only on a part of reinforcing fiber        bundle    -   111 shaping mold (lower mold)    -   112 shaping mold (upper mold)    -   113 layered product    -   121 shaping mold    -   123 sheet    -   124 sealer    -   125 chamber    -   126 vacuum pump    -   127 pressurizing device    -   131 shaping mold (lower mold)    -   132 shaping mold (upper mold)    -   133 layered product    -   134 part mold    -   135 heating means    -   141 shaping mold (lower mold)    -   142 shaping mold (upper mold)    -   143 layered product    -   144 movable part capable of projecting    -   145 heating means    -   151 shaping mold    -   152 layered product    -   153 sheet    -   154 sealer    -   155 part mold    -   156 heater    -   157 vacuum pump    -   158 pressurizing device    -   159 chamber    -   161 edge holding swing mechanism    -   162 wind-off mechanism of fabric substrate    -   163 wind mechanism of fabric substrate    -   164 fabric substrate    -   171 nip swing mechanism    -   181 swing roll    -   182 delivery roll    -   θ shearing deformation angle

DETAILED DESCRIPTION

Hereinafter, our fabrics, preforms, components and methods will beexplained in detail together with preferable forms.

In the reinforcing woven fabric, a resin material is stuck on at leastone surface of a fabric substrate containing a plurality of reinforcingfiber bundles, and the maximum value of load till a tensile strain in anon fiber axial tensile test reaches 1% is in a range of 0.01 to 0.75 N.

A preform with excellent retention of shape can be obtained by stickinga resin material on a fabric substrate. Namely, in producing a preformby laying up reinforcing woven fabrics and providing a shape, the resinmaterial is melted by heating, the molten resin material is penetratedin both facing reinforcing woven fabrics and then cooled/solidified,thereby bonding the interlayer of the reinforcing woven fabrics, as aresult, it is possible to obtain a preform excellent in retention ofshape.

The above-described resin material may be stuck on both surfaces of areinforcing woven fabric. However, in bonding the interlayer of thereinforcing woven fabrics, an interlayer adhesion effect is obtainedwhen there is a resin material on at least one side of facingreinforcing woven fabrics. Hence, when a resin material is stuck on atleast one surface of a reinforcing woven fabric contacting at eachinterlayer by contriving the order of laying up, a sufficientshape-retaining effect by adhesion of interlayer can be obtained.

Further, it is sufficient for a resin material to be stuck at least on asurface of a reinforcing woven fabric, but for example, a resin materialmay be present not only on a surface alone but also inside of areinforcing woven fabric in the case where a fabric is constituted by areinforcing fiber bundle containing a resin material.

As the resin material, it is not particularly limited as long as it canbe stuck on a surface of a fabric substrate containing reinforcing fiberbundles and the interlayer is bonded by pressurizing and heating thereinforcing woven fabrics laid up, and an effect of retaining the shapeof the deformed reinforcing woven fabric can be exhibited. It can besuitably chosen and used from a thermoplastic resin, thermoplastic resinor a mixture thereof. Such resin material is a crystal state or glassstate at room temperature, but it is necessary to have a property tomelt or soften by heat.

Regarding a resin material, for example, after a resin with a shape suchas fiber-form and powdered state is spread on a surface of a fabricsubstrate, it is softened by heat for bonding the resin to a single yarnconstituting a reinforcing fiber bundle, then by a method of cooling andsolidifying, or after a liquid resin is sprayed on a surface of a fabricsubstrate, it is solidified to be stuck on a surface of a fabricsubstrate. It may be stuck by a method other than that as a matter ofcourse.

In the case where a reinforcing woven fabric is deformed into athree-dimensional shape, since the reinforcing woven fabric isconstituted by a reinforcing fiber bundle having a small elongation, thedeformation derived from the elongation of the reinforcing fiber bundleis very small. Therefore, it is necessary to vary a relative positionbetween reinforcing fiber bundles constituting a reinforcing wovenfabric, namely to be deformed into a three-dimensional shape by varyingan angle that yarns constituting a fabric cross.

Further, in the case where a reinforcing woven fabric is deformed into athree-dimensional shape, when each part of a reinforcing woven fabriccan flexibly be deformed even under a small deformation load, the wholeof a reinforcing woven fabric can be deformed largely and smoothly bythe accumulation of very small deformation of each part; as a result, itcan follow a complicated three-dimensional shape without wrinkle. In thecase where a reinforcing woven fabric with a low deformability under asmall deformation load is forcedly deformed into a three-dimensionalshape, each part thereof cannot be deformed till a deformation loadreaches a given value, but when the load exceeds the given value, a partof a low resistance to deformation generates a local deformation.Therefore, as a whole, it cannot follow a three-dimensional shape,generates a large wrinkle, posing problems in designing property,impregnation of resin and all mechanical characteristics.

Hence, to allow a reinforcing woven fabric to follow a three-dimensionalshape without wrinkles it is important that each part of a reinforcingwoven fabric is deformed smoothly even under a small deformation load.

In a fabric substrate on that no resin material sticks, generally, sincethe relative position of reinforcing fiber bundles constituting thefabric is constrained mainly by friction generated between reinforcingfiber bundles, the relative position of reinforcing fiber bundles can bevaried relatively easily, and deformability of reinforcing woven fabricis good.

On the other hand, in a reinforcing woven fabric on that surface a resinmaterial 13 sticks as shown in FIG. 1 and FIG. 2, generally, there areresin materials 11 and 12 stuck over a plurality of reinforcing fiberbundles 14, 15, these resin materials bind, the reinforcing fiberbundles together, thus, a strong force of constraint acts between thereinforcing fiber bundles to worsen the deformability of reinforcingwoven fabric. As a result, in the case of allowing a reinforcing wovenfabric to follow a three-dimensional shape, a necessary deformationtends to hardly occur, and there is a tendency to generate defects suchas generation of wrinkles in deformation into a three-dimensional shape.

However, although the reinforcing woven fabric is a reinforcing wovenfabric where a resin material is stuck on a surface of at least one sideof a fabric substrate containing a plurality of reinforcing fiberbundles, it can be followed into a three-dimensional shape andpreventing the generation of wrinkles while exhibiting an interlayeradhesion effect by a resin material since the maximum value of load tillan tensile strain in a non fiber axial tensile test reaches 1% is in arange of 0.1 to 0.75 N.

The non fiber axial tensile test is to measure displacement and load ina direction of the maximum deformation of reinforcing woven fabric whenan tensile load is applied to an in-plane direction of a reinforcingwoven fabric, specifically, it is according the following method.

First, a rectangular test piece (size of measuring part: length 150mm×width 45 mm) is prepared so that a most deformable direction of areinforcing woven fabric is a longitudinal direction. This test piece isstretched in a longitudinal direction to measure the amount ofdeformation (amount of change in a measuring length) and a tensile loadat the time.

For example, in the case of a bidirectional reinforcing woven fabrichaving fiber axes of fiber reinforcing bundles in two directions of 0°and 90°, a most deformable direction when an tensile load is applied iseither +45° or −45° directions, thus, a test piece is cut out for eitherdirection to be a longitudinal direction (see FIG. 3).

When a non fiber axial tensile test is carried out using this testpiece, a tensile load is applied in a direction different from the fiberaxis direction of reinforcing fiber bundles, being accompanied withwhich, the relative position of reinforcing fiber bundles constituting areinforcing woven fabric is displaced to change an angle that yarnsconstituting a fabric cross. As a result, the test piece is deformed sothat a distance of a measuring part length becomes large (see FIG. 4).Namely, in a non fiber axial tensile test, deformation generated bychanging an angle that yarns constituting a fabric cross is stemmed fromthe same mechanism of deformation required when a reinforcing wovenfabric is followed to a three-dimensional shape, and deformability ofreinforcing woven fabric can be known by measuring the relationshipbetween the load and amount of deformation in a non fiber axial tensiletest. For example, a reinforcing woven fabric with a small load requiredfor giving a certain amount of deformation is superior in deformability,and it can be said to be a reinforcing woven fabric which easily followsa three-dimensional shape.

In a non fiber axial tensile test as shown in FIG. 4, since a test pieceshows a nonuniform deformation, it is necessary to pay attention to ameasuring result varying depending on test piece size. Therefore, a testis to be conducted by using a test piece of the above-described size.

Further, when a tensile load is applied, in the case where a test piecewas deformed in a width direction in a test piece attaching part 41shown in FIG. 4, a test result varies in the same manner. Thus, it isimportant to use an attaching tool of a structure in which a uniformclamp pressure can be applied across the whole width of a test piece inattaching a test piece and to attach a test piece not to be deformed ina width direction in a clamp part.

A tensile strain of 1% in this non fiber axial tensile test means astate in which when a test piece was subjected to a tensile deformationin a longitudinal direction, the measuring part length became large by1.5 mm from an initial length to 151.5 mm.

When the maximum value of load till a tensile strain in a non fiberaxial tensile test reaches 1% is in a range of 0.01 to 0.75 N, it ispossible to follow a three-dimensional shape smoothly because each partin the reinforcing woven fabric can smoothly deformed under a smalldeformation load even in a very small deformation region at thebeginning of deformation, and there is a low possibility to generatedefects such as wrinkles. The upper limit of the maximum value of theload is preferably 0.6 N, further preferably 0.45 N. On the other hand,the lower limit of the maximum value of the load is preferably 0.05,further preferably 0.1. When the maximum value of load required till atensile strain reaches 1% is in a range of 0.05 to 0.6 N, it is furtherexcellent in deformability, when in a range of 0.1 to 0.45 N leads to avery excellent deformability, and it becomes further easy to be deformedinto a three-dimensional shape without wrinkles.

Further, it is preferable for a reinforcing woven fabric that themaximum value of load till a tensile strain in a non fiber axial tensiletest reaches 5% is in a range of 0.1 to 1.0 N. A tensile strain of 5% ina non fiber axial tensile test means a state in which when a test piecewas subjected to a tensile deformation in a longitudinal direction, themeasuring part length became large by 7.5 mm from an initial length to157.5 mm.

In the case of deforming a reinforcing woven fabric into athree-dimensional shape, it is necessary that a part where a shapechanges largely is deformed further largely in addition to accompanyinga very small deformation across almost all of parts deformed into athree-dimensional shape.

When the maximum value of load till a tensile strain in a non fiberaxial tensile test reaches 5% is in a range of 0.1 to 1.0 N, in the casewhere a reinforcing woven fabric needs a large deformation in additionto a very small deformation under a small deformation load, a relativeposition between reinforcing fiber bundles changes easily and, there isa low probability to generate defects such as wrinkles. The upper limitof the maximum value of the load is preferably 0.85 N, furtherpreferably 0.7 N. On the other hand, the lower limit of the maximumvalue of the load is preferably 0.15, further preferably 0.2. When themaximum value of load till a tensile strain reaches 5% is in a range of0.15 to 0.85 N, which is further excellent in deformability, when in arange of 0.20 to 0.70 N leads to a very excellent deformability, and itbecomes further easy to be deformed into a three-dimensional shapewithout wrinkles.

In the reinforcing woven fabric, a resin material is stuck on a surfaceof at least one side. When the resin material stuck on a surface ismuch, it is possible to strengthen a function of bonding the interlayerin the case of laying up a plurality of reinforcing woven fabrics stuckwith a resin material, and it is possible to obtain a preform excellentin retention of the figure shaped. However, when there is too much resinmaterial, deformability is markedly deteriorated because the resinmaterial bonds the reinforcing fiber bundles constituting a reinforcingwoven fabric together too strongly. Further, as shown in FIG. 5, thesurface of a reinforcing woven fabric is widely covered by a resinmaterial 51, and when a liquid matrix resin is infused in a reinforcingwoven fabric to obtain a fiber reinforced plastic molded component,inflow of the matrix resin into the reinforcing woven fabric isdisturbed, which increases the time required for the matrix resin to behomogeneously impregnated thoroughly, or causes a part where no matrixresin is impregnated. From such viewpoints, the stuck amount of resinmaterial is preferably 50 g/m² or less; more preferably 25 g/cm² orless, and further preferably 10 g/m² or less. On the other hand, whenthe resin material stuck on a surface of a reinforcing woven fabric isnot enough, it is not possible to obtain a sufficient adhesive force inbonding the interlayer of the reinforcing woven fabrics and athree-dimensional shape cannot be retained. From such viewpoints, thestuck amount of resin material is preferably 1 g/m² or more, morepreferably 1.5 g/cm² or more, and further preferably 2 g/m² or more.

The resin material stuck on a surface is not particularly limited aslong as it can be stuck on a surface of a fabric substrate by theforegoing method and can obtain a function of bonding the interlayer ofa fabric substrate. A thermosetting resin and/or a thermoplastic resincan be suitably chosen and used, above all, one mainly consisting of athermoplastic resin is preferable. As the thermoplastic resin, forexample, there are polyamide, polysulfone, polyether-imide,polyphenylene ether, polyimide, polyamideimide and the like, but it isnot limited thereto. When the resin material is a thermoplastic resin asa major component, the handling property is improved in the case whereit is spread and stuck on the surface of a reinforcing woven fabric,further, in the case where the reinforcing woven fabric is laid up,deformed in a three-dimensional shape and then the interlayer is bonded,and productivity is improved. Here, a major component means a componenthaving the largest ratio in components constituting a resin material.

In the reinforcing woven fabric, a resin material is preferablyscattered and stuck on the surface of a fabric substrate. Beingscattered means a dispersion state over the whole surface region of afabric substrate. By being scattered, a uniform adhesive force tends tobe obtained in the whole surface upon interlayer adhesion even when theamount of resin material is small. Further in this case, it ispreferable that 90% or more of the resin material scattered and stuck onthe surface of reinforcing woven fabric has a projected area in adirection vertical to the surface of a reinforcing woven fabric in arange of 0.002 to 1 mm². More preferably, it is 0.002 to 0.2 mm², andfurther preferably, it is 0.002 to 0.05 mm². When the projected area isless than 0.002 mm², the number of resin material buried in concavityand convexity accompanied with the fabric architecture of a fabricsubstrate surface is increased to weaken the interlayer adhesion; as aresult, it becomes difficult to retain the figure shaped. Reversely,when the projected area is more than 1 mm², there is a tendency to causevariation in a dispersion state of resin material, it becomes difficultto obtain a uniform adhesion when the interlayer is bonded. Further,there sometimes happens the case that defects tend to generate in theinfusion of a matrix resin described above.

As the fabric substrate constituting the reinforcing woven fabric, it ispossible to suitably choose from ones constituted by a plurality ofreinforcing fiber bundles. For example, there can be used aunidirectional fabric where a plurality of reinforcing fiber bundlesaligned in one, direction to be parallel to each other and an auxiliaryfiber (single yarn or fiber bundle) with a small diameter beingperpendicular to them are tangled with each other to build a fabricarchitecture, or a bidirectional fabric where a plurality of reinforcingfiber bundles are woven in two directions (for example, perpendiculardirections), further, a multi-axial woven fabric where a plurality ofreinforcing fiber bundles aligned each in parallel are laid up inmultistage for respective fiber directions to be different, which areconnected by stitching etc. Among these, a bidirectional fabric ispreferred. As the fabric structure of the bidirectional fabric, a plainfabric, twill fabric, satin fabric or the like is mentioned. Abidirectional fabric has merits that deformation of a fabric substrateis easily done by changing a relative position between reinforcing fiberbundles to be deformed into a three-dimensional shape easily and thatthe layered constitution having a quasi-isotropic mechanical property iseasily obtained with a small number of fabrics, which is preferable.

As the reinforcing fiber bundle constituting a fabric substrate, therecan be used a carbon fiber bundle, graphite fiber bundle, glass fiberbundle, aramid fiber bundle or the like. Among these, a carbon fiberbundle is preferred. As a carbon fiber constituting a carbon fiberbundle, there are many kinds such as polyacrylonitrile based, rayonbased and pitch based ones, and a polyacrylonitrile based carbon fiberis preferably used from the balance of strength and elastic modulus. Byusing a carbon fiber bundle, it is possible to heighten the mechanicalcharacteristics of a fiber reinforced plastic molded component as afinal product. From the those viewpoints, the tensile elastic modulus ofthe carbon fiber bundle is preferably 110 to 600 GPa, and if 210 to 600GPa, it is preferable because further excellent mechanicalcharacteristics can be exhibited. The tensile elastic modulus means avalue measured in accordance with JIS R7601 (1986) and unit is GPa.

The reinforcing woven fabric as described above can be produced asfollows; a resin material is provided and stuck on a surface of at leastone side of a fabric substrate containing a plurality of reinforcingfiber bundles, and then the relative position of a plurality ofreinforcing fiber bundles constituting the fabric substrate is varied.

The resin material can be stuck on the surface of a fabric substrate bythe foregoing method. As shown in FIG. 6 and FIG. 7, even in the casewhere there is a resin material stuck over a plurality of reinforcingfiber bundles, by giving a larger external force than a force ofconstraining a positional variation between reinforcing fiber bundlesgenerated by a stuck resin material, the relative position betweenreinforcing fiber bundles constituting a fabric substrate is forcedlyvaried, as shown in FIG. 8 and FIG. 9, it is possible to produce acondition in which a resin material is stuck only on a part ofreinforcing fiber bundles.

The resin particle stuck over two reinforcing fiber bundles is generallystuck more strongly on either of the reinforcing fiber bundles. Thus,the resin material moves together with a reinforcing fiber bundle stuckmore strongly when the relative position between the two reinforcingfiber bundles stuck with the resin material is varied; as a result, itis peeled from the other reinforcing fiber bundle.

In this manner, by varying the relative position between the reinforcingfiber bundles forcedly by an external force, the resin material stuck ontwo or more reinforcing fiber bundles is peeled from a part of thereinforcing fiber bundles, resulting in a state in which it is stuckonly on a reinforcing fiber bundle stuck more strongly.

As a result, there is no function of constraining the deformation ofresin material even in a reinforcing woven fabric on that surface aresin material sticks, and then it comes to have a property that themaximum value of load till an tensile strain in a non fiber axialtensile test reaches 1% is in a range of 0.01 to 0.75 N, so that thesame level of excellent deformability as the fabric substrate thatsticks no resin material.

As a whole reinforcing woven fabric, it may not be excluded to remain aresin material stuck partially over a plurality of reinforcing fiberbundles as it is not being peeled from the reinforcing fiber bundles.

Further, to peel adhesion of resin material from reinforcing fiberbundles by varying a relative position between a plurality ofreinforcing fiber bundles constituting a fabric substrate, a resinmaterial must be substantially in a solid state. Namely, the relativeposition of reinforcing fiber bundles is varied after sufficientlycooling in the case where a resin material is stuck by a thermaladhesion, and after sufficiently drying in the case where it is sprayedas a solution. In this way, the resin material stuck can efficiently bepeeled.

In the case where the relative position between reinforcing fiberbundles is once varied, even though the positional relation is returnedto the original, the peeled resin material does not stick again as longas the resin material is not softened by reheating etc., so that if thereinforcing woven fabric is returned to the original shape after beingvaried, no weave pattern is disrupted and it is possible to obtain areinforcing woven fabric retaining the same fabric structure as thatbefore being varied.

The method for varying a relative position between reinforcing fiberbundles may be any method so long as to obtain a function of varying arelative position between reinforcing fiber bundles by overwhelming aforce of constraint generated through adhesion between reinforcing fiberbundles by a resin material. For example, a relative position betweenreinforcing fiber bundles may efficiently be varied by giving a shearingdeformation in an in-plane direction of a fabric substrate on thatsurface a resin material sticks.

To give a shearing deformation to a fabric substrate, for example, theremay be used an apparatus having a wind-off mechanism for a fabricsubstrate on that a resin material stuck, a swing mechanism givingdeformation in a width direction by swinging a fabric substrate in thewidth direction while holding it and a wind mechanism of a fabricsubstrate.

The wind-off mechanism is constituted by an axis for placing a roll of afabric substrate on that a resin material stuck, and a mechanism forgiving a suitable tension to a fabric substrate to be wound off from theroll. The mechanism for giving a tension may use any mechanism as longas it can give a tension to a fabric substrate to be delivered, forexample, a mechanism for giving a tension through connection to anapparatus such as powder brake giving a torque to an axis that a roll isplaced with, a mechanism for giving a tension through nip of fabricsubstrate to be delivered by a pair of rolls whose rotation iscontrolled, or a mechanism for giving a tension by a frictional forcebetween a roll whose rotation is controlled and a fabric substrate.

The swing mechanism for swinging a fabric substrate in the widthdirection may use any constitution as long as it can swing a fabricsubstrate in the width direction. For example, there can be exemplifiedan edge-holding swing mechanism 161 holding an edge of a fabricsubstrate in the width direction and giving a tension in the widthdirection shown in FIG. 16, or a nip swing mechanism 171 nipping afabric substrate from up and down with a tool and swinging the tool inthe width direction of a fabric substrate as shown in FIG. 17. As shownin FIG. 18, there is also preferably used a mechanism of swinging whileholding a fabric substrate with frictional force by swinging a swingroll 181 in which the width direction of a fabric substrate is therotational axis direction to its rotational axis direction.

In the case of using the mechanism shown in FIG. 18, it is preferable toarrange the swing roll 181 for which a fabric substrate pass with alarge wrapping angle, since a large frictional force is obtained againsta reinforcing woven fabric, and the fabric substrate can efficiently beswung. Herein, the wrapping angle is referred to an angle in which afabric substrate wraps to a circumference of the swing roll when passingthrough the swing roll 181 from a delivery roll 182 to move to a nextdelivery roll 182.

Further, by increasing the friction coefficient of a roll surface usinga rubber material for the roll surface for example, it is possible for afabric substrate not to slip on the roll surface in swinging the fabricsubstrate in the width direction. By doing this, as well as the fabricsubstrate can further efficiently be swung, it is possible to prevent asurface of the fabric substrate from damage of abrasion by slip on aroll surface. Similarly, not to give any damage to the fabric substrate,a driven rotation of a swing roll in accompanying with the run of afabric substrate is preferable.

The length of delivery path changes when a fabric substrate is swung inthe width direction. Therefore, as shown in FIG. 19, when the swing roll181 swings in the axial direction, it is preferable to have a mechanismcapable of moving in a direction perpendicular to the rotational axis aswell in order to absorb the change of path length.

The wind mechanism may be a constitution in which a fabric substrate iswound on a roll by rotation of an axis that the roll is disposed.Winding may be a continuous operation at a constant speed, or may be anintermittent operation repeating winding and stopping in such mannerthat, for example, it stops in operation of a swing mechanism andwinding is done in stop time of a swing mechanism.

For example, when a shearing deformation is given to a bidirectionalfabric substrate shown in FIG. 1 by the foregoing method, the fabricsubstrate is deformed as shown in FIG. 10. When a shearing deformationis given to a rectangular part in which intersections of reinforcingfiber bundles are apexes the rectangular part is deformed into aparallelogram while keeping the length of respective sides. At thistime, an angle between reinforcing fiber bundles constituting a fabricis deformed, and a relative position between reinforcing fiber bundlesis varied. As a result, it is possible to peel the resin material stuckover a plurality of reinforcing fiber bundles partly from thereinforcing fiber bundles.

The angle θ of shearing deformation shown in FIG. 10 (namely, using acertain reinforcing fiber bundle as a standard, an angle differencebetween before and after shearing deformation of reinforcing fiberbundles crossing to the standard) is preferably in a range of 5 to 45°.When the shearing deformation angle is less than 5°, it is not possibleto obtain an effect of peeling the resin material stuck over a pluralityof reinforcing fiber bundles sufficiently because of insufficientvariation of a relative position between reinforcing fiber bundles. Onthe other hand, when the shearing deformation angle is more than 45°,disturbance of fabric texture is left, or defects such as generation ofdamage in a reinforcing woven fabric occurs easily when the reinforcingwoven fabric is deformed and then tried to return to the original shape.That is why it is not preferable. To obtain an effect of peeling a resinmaterial more efficiently, the shearing deformation angle is morepreferably 10° or more, and further preferably 20° or more. On the otherhand, to prevent the damage of a reinforcing woven fabric more surely,the shearing deformation angle is more preferably 40° or less, andfurther preferably 30° or less.

By using the thus obtained reinforcing woven fabric, it is possible toobtain a preform without wrinkles even in a three-dimensional shape.

The preform is formed by laying up the reinforcing woven fabric togetherwith a fabric substrate that does not stick a resin material accordingto need, and integration thereof. In the preform, a plurality of fabricsubstrates are integrated by a resin material and also it contains atleast one layer of the reinforcing woven fabric stuck with the resinmaterial.

Resulting from bonding a plurality of fabric substrates deformed in athree-dimensional shape with each other via a resin material in theinterlayer, the preform retains its three-dimensional shape. In asurface where the fabric substrates laid up contact each other, when aresin material is stuck on the surface of at least one side of a fabricsubstrate, an adhesion action in the interlayer can be obtained. Hence,considering the shape of the reinforcing woven fabric in actual use, apart of the whole necessary fabric substrates constituting a preform maybe replaced by the reinforcing woven fabric. Namely, when a resinmaterial is stuck on both surfaces of a fabric substrate constitutingthe reinforcing woven fabric, the reinforcing woven fabric and otherfabric substrate may alternately be disposed. Further, when it is enoughfor a part of fabric substrates constituting a preform to be stuck, thenumber of other fabric substrate may be increased.

However, when an adhesion action by a resin material can be obtained inevery interlayer, there can be obtained a preform which has no peeledinterlayer, an excellent handling property, no wrinkles efficiently andan excellent shape stability as well. Therefore, in the case where adesired preform is a complicated shape, thus, where an adhesion actionin every interlayer is required, it is preferable that the reinforcingwoven fabric where a resin material is stuck on both surfaces of afabric substrate and other fabric substrate may alternately be disposed,or the total numbers of necessary fabric substrates constituting apreform, or the numbers except one substrate are set to the reinforcingwoven fabrics. A preform which is not peeled as a whole and excellent inhandling property can be obtained thereby. The total numbers ofnecessary fabric substrates constituting a preform may be thereinforcing woven fabrics where a resin material is stuck on both thesurfaces as a matter of course.

A preform using the reinforcing woven fabrics can be formed as follows.

First, the reinforcing woven fabrics is laid up in a shaping moldtogether with other fabric substrate containing reinforcing fiberbundles according to need. Next, the layered product is pressurized andheated while being imposed to follow a shape of the shaping mold, whichsoftens a resin material stuck on the reinforcing woven fabrics to bondthe interlayer of the layered product and to retain the shape. In thisway a preform is obtained.

As a method for pressurizing a layered product, for example, there canbe exemplified a method in which using a pair of shaping molds capableof shaping almost the same shape as that of a desired fiber reinforcedplastic molded component (namely, a mold having almost the same moldshape as the molding tool in which a matrix resin is infused and cured),after the layered product is laid up in one shaping mold, the othershaping mold is closed and tighten up, while pressurizing the layeredproduct, which is deformed into a shape along the shaping mold (see FIG.11). Further, there can be exemplified a method in which using a shapingmold of one surface having almost the same shape as the molding tool,after the layered product is laid up on the shaping mold, from which thelayered product is covered with a sheet, the inside of a spacesurrounded by the sheet and the shaping mold is vacuumed, or apressurized gas is introduced into a chamber, thereby the layeredproduct is pressurized via the sheet, and imposed on the shaping mold tobe deformed into a shape along the shaping mold (see FIG. 12). It is notlimited thereto. Further, a pair of shaping molds described above may bea type in which one of shaping molds constituting it may be divided tobe plural pieces.

As a method for heating a layered product, there can be exemplified amethod by heat conduction of a heated shaping mold and layered product,a method of heating from outside by an infrared heater etc., or a methodof spraying a heated gas or liquid, but it is not particularly limited.The shaping mold can be heated by a method in which a pipe arrangementis provided inside and a heat medium is run in the pipe arrangement, ora heater is provided inside.

To produce a preform efficiently, it is preferable to use a method inwhich a layered product is tightly contacted with a shaping mold heatedat a temperature required for softening a resin material to heat by heatconduction. In this case, when a resin material is softened beforedeforming a layered product into a shape along a shaping mold, there isa case in which adhesion of the resin material increases and theinterlayer of the layered product is hardly slide and deformation into athree-dimensional shape becomes difficult. Thus, it is preferable to bepressurized and deformed before heat conducts a resin material.

The temperature of heating a layered product may be a temperature whichcan exhibit an action to bond the interlayer of a layered product bysoftening a resin material. By heating a layered product whilepressurizing it, the reinforcing woven fabric and fabric substrateconstituting a layered product are imposed on each other, the resinmaterial which was softened penetrates between single yarns ofreinforcing fiber bundles constituting the facing reinforcing wovenfabric and fabric substrate. Next, by cooling the layered product, theresin material sticks both the facing reinforcing woven fabric andfabric substrate, and exhibits an action to bond the interlayer of thelayered product. As a method for cooling a layered product, there can beexemplified a method of heat conduction of a shaping mold and layeredproduct by cooling a shaping mold, or a method of spraying a cold air toa layered product, but it is not particularly limited.

In such ways, by deforming a layered product into a three-dimensionalshape and bonding the interlayer, a preform without wrinkles in spite ofbeing deformed into a three-dimensional shape can be produced. Further,regarding this preform, since the interlayer of a layered product isbonded, it has features that rigidity is high and shape retention isexcellent, and also handling of preform in delivery, arrangement in amolding tool to infuse a matrix resin and the like can be efficientlyconducted.

Further, a preform can also be produced by disposing a layered productbetween facing at least two shaping molds, pressurizing a part of thelayered product, and then heating the remaining part as well aspressurizing. In the method, when a layered product is disposed betweenthe shaping molds and a part of the layered product is pressurized, apart not pressurized in the layered product is not in constraint, thusit can move freely, and the amount of the layered product necessary tofollow a shape of the shaping mold is gathered from the circumference.Next, when a circumference part is pressurized, the whole of the layeredproduct is pressurized and deformed along the shape of the shaping mold.The layered product is heated in a state along the shape of the shapingmold, and a resin material is softened to become a preform that theinterlayer is bonded. By pressurizing the whole after pressurizing apart thereof first, in particularly, even in a concavity and convexitychanging its shape largely, the necessary amount of the layered productto follow the shape of the shaping mold is supplied without delay sothat a preform without wrinkles can be efficiently produced with noassist by a hand operation.

The place being pressurized before the whole of a layered product ispressurized is not particularly limited; for example, in the case wherea layered product is deformed into a relatively smooth shape, it ispreferably around the center of such shape because the layered productis easily pulled in from the circumference. In the case where a layeredproduct is deformed into a shape with a bump, it is preferably theconcavity of the bump. When the concavity is first pressurized, anecessary and sufficient amount of layered product for a layered productto be deformed into a shape along the concavity is supplied, which canshape it well. Further, for a shape with a plurality of bumps, it ispressurized stepwise in such way that the adjacent concavities aresubsequently pressurized and the remaining all is finally pressurized,thereby a preform can be effectively produced while preventing thegeneration of wrinkles.

As a method for pressurizing and heating a remaining part after a partof a layered product has been pressurized, as shown in FIG. 13, therecan be exemplified a method that to a layered product 133 laid up on ashaping mold 131, a pressurizing action is given by a part mold 134,subsequently, the whole is held by a shaping mold 132 oppositely placed,pressurized and heated. A part mold means a member for deforming a partof a layered product into a shape along a shaping mold. By pressurizinga layered product using the part mold, the layered product is sandwichedbetween a shaping mold and the part mold to be deformed into a shapealong a shaping mold.

The part mold, in a part for pressurizing a layered product, must have ashape along a shaping mold corresponding to the part, and also in a partnot contacting a layered product, must have a shape not to disturb anaction that a shaping mold or a sheet holds and pressures a layeredproduct. As the part mold, there can be used one that a material such asmetal, resin or rubber is cut or processed into a desired shape. To heata layered product efficiently, a part mold is preferably heated, butwhich is not essential because a layered product is heated from ashaping mold as well.

A part mold, as shown in FIG. 14, may be constituted of a movable part144 capable of projecting being provided in at least one side of facingshaping molds 141 and 142. In this embodiment, first, the shaping moldsare made adjacent to each other in a state projecting the movable part144, a part of a layered product 143 is pressurized by other shapingmold 141 and the projected movable part. Next, the shaping molds aremade more adjacent to each other and also the projected movable part 144is pulled to the inside direction of the shaping mold, the whole layeredproduct is pressurized and heated by the whole of the facing shapingmolds 141 and 142.

Further, a preform can also be produced in such way that after a part ofa layered product laid up in a shaping mold is imposed on the shapingmold, a sheet is covered on the layered product, the layered product ispressurized and heated by gas or liquid. In the method, as shown in FIG.15 for example, a part of a layered product 152 laid up in a shapingmold 151 is imposed on the shaping mold by a part mold 155, and a partof a layered product is deformed into a shape along the shaping mold.The shape of the part mold is set to be along the corresponding part ofthe shaping mold. At this time, a part of a layered product not imposedis not in constraint, thus it can move freely, and the amount of thelayered product necessary to follow the shaping mold is pulled in fromthe circumference. Next, the layered product can be pressurized in suchmanner that a sheet 153 is covered on the layered product, a gap betweenthe circumferential part and the shaping mold is sealed by a sealer 154,and inside of the space surrounded by the shaping mold and the sheet 153is vacuumed by a vacuum pump 157 or, gas or liquid inside the spacesurrounded by the sheet 153 and a chamber 159 is pressurized by using apressurizing device 158. Further, a layered product can be heated byheating a shaping mold by a heater 156 or, by heating gas or liquid. Indoing so, a preform can be produced in such manner the whole of alayered product is deformed into a shape along the shaping mold, furthera resin material inside the layered product is softened and theinterlayer adhesion action is exhibited.

As a material of sheet, there is listed a silicone rubber, naturalrubber, nylon resin, polyethylene resin, polypropylene resin or thelike, but it is not limited thereto.

A sheet which is stretchable is preferable because it follows a shapeeasily even if a desired shape of preform is complicated. Hence, adegree of elongation of a sheet is preferably 5% or more. Additionally,it is no problem that a degree of elongation of a film is large, inviews of repeated use, heating and the like; the upper limit in a degreeof elongation of film answering in an actual use is preferably 400%.

Further, it is effective for an efficient deformation of a layeredproduct in which a sheet is previously shaped in almost the same shapeas the shape in which a layered product is to be deformed.

The fiber reinforced plastic molded component can be produced byinfusing and impregnating a liquid matrix resin into a preform producedby the foregoing method, followed by curing or solidifying the resin.

The above-described preform excellent in shape retention while beingdeformed without wrinkle is hard to undergo the collapse of shape bycarrying it, and easy to handle, so that it can be easily placed in amolding tool. Further, since it is excellent in shape retention, theexternal shape is clear, and positioning is easy when it is placed in amolding tool.

As a method for impregnating a resin, there can preferably be used amethod in which after a preform is placed on a one-face mold, it iscovered with a film, inside of the space surrounded by the film andmolding tool is vacuumed, then a liquid resin is impregnated in thepreform under vacuum pressure, or a method that a preform is sandwichedby facing molding tools, and a matrix resin is pressure-impregnated intoa mold. Next, a fiber reinforced plastic molded component can beproduced by curing or solidifying a resin at a temperature and timesuitable for the resin, followed by demolding.

As the matrix resin, it is not particularly limited, for example,thermosetting resins such as an epoxy resin, phenol resin, vinylesterresin and unsaturated polyester resin are preferably used. Among these,an epoxy resin can particularly preferably be used because of excellenthandling property and mechanical characteristic.

Since the fiber reinforced plastic molded component uses a reinforcingwoven fabric excellent in deformability into a curved surface shape orthree-dimensional shape, it can be produced with a good productivityeven for a complicated three-dimensional shape; further, since it uses acontinuous reinforcing fiber, it can exhibit an excellent mechanicalcharacteristic regardless of light weight. A three-dimensional shapemeans a shape combined with a plain surface and a curved surface (shapehaving a branch in cross section is included).

Further, since the reinforcing woven fabric used in the fiber reinforcedplastic molded component has features that displacement of weave textureand wrinkles hardly take place, disarray is few in a weave texturepattern characteristic of a fabric substrate appearing on a surface of afiber reinforced plastic molded component, and the designing property isexcellent and, further, since orientation disarray of reinforcing fiberbundles is few, mechanical characteristics are excellent as well. Basedon these features, the fiber reinforced plastic molded component canpreferably be used for exterior members and structural members requiringa complicated shape, designing property and high mechanicalcharacteristic in applications such as an automobile, airplane, marinevessel, home electric appliance and building.

EXAMPLES

Hereinafter, our fabrics, preforms, components and methods will beexplained on the basis of Examples and Comparative Examples.

Example 1

On one surface of a bidirectional fabric substrate, a particulate resinmaterial mainly containing a polyvinyl formal resin was dropped using anemboss roll and a doctor blade while weighing for the mass per unit areato be 5 g/m², and spread homogeneously. Subsequently, the resin materialwas stuck on the fabric substrate by passing it under a far-infraredheater at 0.3 m/min set for a surface temperature of the fabricsubstrate to be 185° C., and a reinforcing woven fabric on that surfacethe resin material stuck was wound up on a roll.

As the bidirectional fabric substrate, there was used CO6343B producedby Toray Industries, Inc. (weave structure: plain fabric, unit weight ofwoven fabric: 198 g/m², thickness: 0.25 mm, warp weaving density: 12.5yarns/25 mm, weft weaving density: 12.5 yarns/25 mm), the reinforcingfiber bundle used in this bidirectional fabric substrate was a carbonfiber T300-3K produced by Toray Industries, Inc. (number of filaments:3,000, tensile elastic modulus: 230 GPa, tensile strength 3.5 GPa,fineness: 198 tex, rupture elongation: 1.5%).

Subsequently, this reinforcing woven fabric was wound off from a roll,passed a swing roll capable of swinging in an axial direction at awrapping angle of 180°, and wound on another roll. The reinforcing wovenfabric was intermittently moved from a winding-off side to a windingside, the swing roll was swung during stopping of the intermittentoperation, a deformation history was given such that a shearingdeformation angle toward the in-plane direction to the reinforcing wovenfabric was 30° at the maximum. Then, the reinforcing woven fabric waswound up on a roll when the shearing deformation angle was returnedsubstantially to a 0° state. The surface of this reinforcing wovenfabric was observed to find that the resin material was scattered andstuck on the surface of the fabric substrate. Further, no peeling ofresin material from the fabric substrate was observed due to shearingdeformation.

Then, from the reinforcing woven fabric wound up, given that thedirections of warp and weft were 0° and 90° respectively, a test pieceof 250 mm×45 mm in size was cut out for the 45° direction to be alongitudinal direction. Next, 50 mm each of both ends of this test piecein the longitudinal direction was fixed by a jig, and positioned on ameasuring apparatus via jigs of both ends. The reinforcing woven fabricwas fixed so that the part fixed by the jig was not deformed in thewidth direction, and the exposed part between the jigs of both ends wasset to be 150 mm in the longitudinal direction and 45 mm in the widthdirection. Additionally, as the measuring apparatus, an AutographAGS-100 produced by SHIMADZU CORPORATION was used.

Thereafter, a non fiber axis tensile test where a test piece wasstretched via jigs in the longitudinal direction was carried out, a loadwas continuously measured till the tensile strain of the test piece(corresponding a displacement in tensile test apparatus) reached 5%(corresponding a displacement of 7.5 mm in tensile test apparatus), therelationship between deformation and load of a test piece was obtained.Since a variation was thought to be present in the measurement, threetest pieces were prepared, each test piece was measured for the maximumloads when strain reached 1% (displacement of 1.5 mm in tensile testapparatus) and 5% (displacement of 7.5 mm in tensile test apparatus)were recorded, and an average of three test pieces was defined as amaximum of load in each tensile strain.

As the result of measurement in this procedure, the maximum value(average of the three pieces) of load provided till the tensile strainreached 1% was 0.24 N, and the maximum value (average of the threepieces) of load provided till the tensile strain reached 5% was 0.5 N.

Subsequently, four rectangles each of 500 mm×400 mm in size were cutfrom the reinforcing woven fabric. At this time, given that directionsof the sides of the rectangle were 0° and 90° respectively, they weretwo pieces that fiber axis directions were almost 0° and 90° directionsand two pieces that the directions were almost ±45°. The reinforcingwoven fabrics cut were laid up in such way that only the reinforcingwoven fabric for the uppermost surface was set for the surface stuckwith a resin material to be on the downside and ones other than whichwere set for the surface stuck with a resin material to be on theupside. Further, two pieces of uppermost and lowermost were those whosefiber axis directions were 0°/90° directions and two pieces of innerlayers were those whose fiber axis directions were ±45° directions. Theresulting layered product was placed on a shaping mold heated at 90° C.Here, as the shaping mold, one having a planar size of 450 mm×350 mm,and a groove of 40 mm in depth drawing a curve with a slope angle of 45°was used.

After that, the layered product was sandwiched by the shaping mold andthe facing shaping mold heated at 90° C., a pressure of 0.4 MPa wasgiven to the layered product for 5 minutes. It took about 10 secondsfrom the placement of the layered product on the shaping mold till thelayered product being sandwiched by the two shaping molds.

The facing shaping molds were demolded, the layered product cooled bycold blast was taken out from the shaping molds to find that the layeredproduct was deformed in a shape along the shape of the shaping molds andthe shape was fixed. No wrinkle occurred on the surface of the layeredproduct provided with the shape. No interlayer of the layered productwas peeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkles occurred on the surface and thesame shape as the shaping mold was exhibited, further, and nodeformation from the shape was excellent, so that it was very preferableas a preform for a fiber reinforced plastic molded component.

This preform was placed in a lower mold of a both-face mold for RTMmolding held at 100° C., an upper mold was closed, and air inside themold was exhausted by a vacuum pump. Next, a liquid epoxy resin wasinfused in the mold at an infusing pressure of 0.5 MPa, impregnated inthe preform and left for 20 minutes. In this way, a fiber reinforcedplastic molded component was obtained. As the resin, there was used aliquid epoxy resin obtained by blending a base resin: “Epicote” 828(produced by Yuka Shell Epoxy K.K.: epoxy resin), and a hardener: BlendTR-C35H produced by Toray Industries, Inc. (imidazole derivative).

In the fiber reinforced plastic molded component obtained, the resin wassufficiently spread across overall and cured, and there was no partwhere the resin was not impregnated and reinforcing fiber bundles wereexposed outwards. Further, the molded component had no largedisplacement in the weave texture of the reinforcing woven fabric whichappeared on the surface of molded component, had a smooth surfacewithout wrinkles; and was excellent as a fiber reinforced plastic moldedcomponent.

Example 2

The same reinforcing woven fabric as in Example 1 was laid up in thesame layered constitution (size: 500 mm×400 mm, the laid-up number: 4).

This layered product was placed on a one-face shaping-mold of the sameshape as in Example 1 being held at room temperature. Then, a siliconrubber sheet of 2 mm thick was covered on the shaping mold and thelayered product, the shaping mold and the sheet were sealed with asealant tape. In this way, a space surrounded by the shaping mold andthe sheet became a sealed space in which the layered product wasconfined. After that, air inside the sealed space was exhausted using avacuum pump, the layered product was imposed on the shaping mold byatmospheric pressure through the sheet. In this condition, hot waterflowed in a pipe arrangement provided in the shaping mold to raise thetemperature of the shaping mold to 90° C. and held for 5 minutes. Thesheet was taken out from the shaping mold, the layered product cooled bycold blast was taken out from the shaping molds to find that the layeredproduct was deformed in a shape along the shape of the shaping molds andthe shape was fixed. No wrinkles occurred on the surface of the layeredproduct provided with the shape. No interlayer of the layered productwas peeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkles occurred on the surface and thesame shape as the shaping mold was exhibited, further, and nodeformation from the shape was excellent, so that it was very preferableas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wassufficiently spread across overall and cured, and there was no partwhere the resin was not impregnated and reinforcing fiber bundles wereexposed outwards. Further, the molded component had no largedisplacement in the weave texture of the reinforcing woven fabric whichappeared on the surface of molded component, had a smooth surfacewithout wrinkles, and was excellent as a fiber reinforced plastic moldedcomponent.

Example 3

A reinforcing woven fabric stuck with resin particles was produced inthe same manner as in Example 1 except that the amount of resin materialstuck on the surface of a fabric substrate was 10 g/m², and the samedeformation history as in Example 1 was given thereto. The surface ofthe fiber reinforced plastic molded component obtained was observed tofind that the resin material was scattered and stuck on the surface ofthe fabric substrate. Further, there was no peeling of the resinmaterial from the fabric substrate due to giving a shearing deformation.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 0.24 N, and the maximum value (average of thethree pieces) of load provided till the tensile strain reached 5% was0.55 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, the layered product wasdeformed in a shape along the shape of the shaping mold and the shapewas fixed. Further, no wrinkles occurred on the surface of the layeredproduct provided with the shape. No interlayer of the layered productwas peeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkle wrinkles occurred on the surface andthe same shape as the shaping mold was exhibited, further, and nodeformation from the shape was excellent, so that it was very preferableas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wassufficiently spread across overall and cured, and there was no partwhere the resin was not impregnated and reinforcing fiber bundles wereexposed outwards. Further, the molded component had no largedisplacement in the weave texture of the reinforcing woven fabric whichappeared on the surface of molded component, had a smooth surfacewithout wrinkles, and was excellent as a fiber reinforced plastic moldedcomponent.

Example 4

A reinforcing woven fabric was produced in the same manner as in Example1 except that BT70-20 produced by Toray Industries Inc. (weavestructure: plain fabric, unit weight of woven fabric: 213 g/m², warpweaving density: 3.27 yarns/25 mm, weft weaving density: 3.27 yarns/25mm) was used in a bidirectional fabric substrate. Additionally, thereinforcing fiber bundle used in this bidirectional fabric substrate wasa carbon fiber T700S-12K produced by Toray Industries Inc. (number offilaments: 12,000, tensile elastic modulus: 230 GPa, tensile strength4.9 GPa, fineness: 800 tex, rupture elongation: 2.1%).

The same deformation history as in Example 1 was given to thisreinforcing woven fabric. The surface of the fiber reinforced plasticmolded component obtained was observed to find that the resin materialwas scattered and stuck on the surface of the fabric substrate. Further,there was no peeling of the resin material from the fabric substrate dueto giving a shearing deformation.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 0.17 N, and the maximum value (average of thethree pieces) of load provided till the tensile strain reached 5% was0.4 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, the layered product wasdeformed in a shape along the shape of the shaping molds and the shapewas fixed. No wrinkles occurred on the surface of the layered productprovided with the shape. No interlayer of the layered product waspeeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkle wrinkles occurred on the surface andthe same shape as the shaping mold was exhibited, further, and nodeformation from the shape was excellent, so that it was very preferableas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wassufficiently got across overall and cured, and there was no part wherethe resin was not impregnated and reinforcing fiber bundles were exposedoutwards. Further, the molded component had no large displacement in theweave texture of the reinforcing woven fabric which appeared on thesurface of molded component, had a smooth surface without wrinkles, andwas excellent as a fiber reinforced plastic molded component.

Example 5

A preform was formed in the same way as in Example 1 except that thefollowing was done in laying up a reinforcing woven fabric and deformingthe layered product.

As the shaping mold, a shaping mold having a planer size of 450 mm×350mm, a first concavity of 30 mm in depth drawing a curve with a slopeangle of 45°, and further, a second concavity at the bottom of the firstconcavity, having 30 mm in a depth from the bottom with a slope angle of45° was used, on which the layered product was placed. The temperatureof the shaping mold was set to 90° C. After that, using a part mold ofthe same shape as the second concavity of the shaping mold being heatedat 90° C., the layered product was imposed on the second concavity andpressurized. Thereafter, the facing shaping mold having the same shapeas the first concavity was provided, a pressure of 0.4 MPa was given tothe layered product entirely including a part not pressurized by thepart mold for 5 minutes. It took about 15 seconds from the placement ofthe layered product on the shaping mold till the facing shaping moldbeing provided and the whole layered product being pressurized.Thereafter, the facing shaping molds and the part mold were demolded,the layered product cooled by cold blast was taken out from the shapingmolds to find that the layered product was deformed in a shape along theshape of the shaping molds having two concavities and the shape wasfixed. Further, no wrinkles occurred on the surface of the layeredproduct provided with the shape. No interlayer of the layered productwas peeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkle occurred on the surface and the sameshape as the shaping mold was exhibited, further, and retention of theshape was excellent, so that it was very preferable as a preform for afiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 except that the shape of a shaping mold used in thispreform was different to obtain a fiber reinforced plastic moldedcomponent. As the shaping mold, one with a shape having a firstconcavity and a second concavity similar to this preform was used. Inthe fiber reinforced plastic molded component obtained, the resin wassufficiently spread across overall and cured, and there was no partwhere the resin was not impregnated and reinforcing fiber bundles wereexposed outwards. Further, the molded component had no largedisplacement in the weave texture of the reinforcing woven fabric whichappeared on the surface of molded component, had a smooth surfacewithout wrinkles and was excellent as a fiber reinforced plastic moldedcomponent.

Example 6

A reinforcing woven fabric on that surface resin particles stuck wasproduced in the same manner as in Example 1 except that the amount ofresin material stuck on the surface of a fabric substrate was 3 g/m²,and the same deformation history as in Example 1 was given thereto. Thesurface of the fiber reinforced plastic molded component obtained wasobserved to find that the resin material was scattered and stuck on thesurface of the fabric substrate. Further, there was no peeling of theresin material from the fabric substrate due to giving a shearingdeformation.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 0.23 N, and the maximum value (average of thethree pieces) of load provided till the tensile strain reached 5% was0.5 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, the layered product wasdeformed in a shape along the shape of the shaping mold and the shapewas fixed. Further, no wrinkles occurred on the surface of the layeredproduct provided with the shape. No interlayer of the layered productwas peeled, the shape deformed in three-dimension was stable, and nodeformation occurred in picking the edge to lift. Namely, in the preformobtained by this method, no wrinkles occurred on the surface and thesame shape as the shaping mold was exhibited, further, and retention ofthe shape was excellent, so that it was very preferable as a preform fora fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wassufficiently spread across overall and cured, and there was no partwhere the resin was not impregnated and reinforcing fiber bundles wereexposed outwards. Further, the molded component had no largedisplacement in the weave texture of the reinforcing woven fabric whichappeared on the surface of molded component, had a smooth surfacewithout wrinkles, and was excellent as a fiber reinforced plastic moldedcomponent.

Comparative Example 1

A reinforced woven fabric (stuck amount of resin material: 5 g/m²) wasproduced in the same manner as in Example 1 except that no shearingdeformation in an in-plane direction was given.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 1.5 N, and the maximum value (average of the threepieces) of load provided till the tensile strain reached 5% was 2.2 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, on the surface of the layeredproduct deformed, many displacements in the weave texture of thereinforced woven fabric were observed, a lot of wrinkles occurredparticularly in the part of a large three-dimensional deformation, andit was not deformed in the same shape as that of the shaping mold. Onthe other hand, no interlayer of the layered product was peeled, and nodeformation occurred in picking the edge to lift. Namely, the preformobtained by this method was excellent in the point of retention of theshape, but a lot of wrinkles occurred on the surface and the shape alongthe shaping mold was not exhibited, so that it was not suitable for useas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wasspread across almost overall and cured, but in the thickened part of thelayered product due to wrinkles, the resin was not sufficientlyimpregnated, and reinforcing fiber bundles were exposed outwards.Further, the resin layer partially became thick in the periphery, beingaccompanied with which, the surface came to be not smooth. Further, inthe weave texture of the reinforcing woven fabric which appeared on thesurface, there was large displacement. Namely, the fiber reinforcedplastic molded component obtained was not suitable for use.

Comparative Example 2

The same reinforced woven fabric (stuck amount of resin material: 5g/m²) as in Comparative Example 1 was laid up in the same layeredconstitution.

This layered product was deformed in the same way using the same shapingmold as in Example 2. As a result, on the surface of the layered productdeformed, many displacements in the weave texture of the reinforcedwoven fabric were observed, a lot of wrinkles occurred particularly inthe part of a large three-dimensional deformation, and it was notdeformed in the same shape as that of the shaping mold. On the otherhand, no interlayer of the layered product was peeled, and nodeformation occurred in picking the edge to lift. Namely, the preformobtained by this method was excellent in the point of retention of theshape, but a lot of wrinkles occurred on the surface and the shape alongthe shaping mold was not exhibited, so that it was not suitable for useas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wasspread across almost overall and cured, but in the thickened part of thelayered product due to wrinkles, the resin was not sufficientlyimpregnated, and reinforcing fiber bundles were exposed outwards.Further, the resin layer partially became thick in the periphery, beingaccompanied with which, the surface came to be hot smooth. Further, inthe weave texture of the reinforcing woven fabric which appeared on thesurface, there was large displacement. Namely, the fiber reinforcedplastic molded component obtained was not suitable for use.

Comparative Example 3

A reinforced woven fabric (stuck amount of resin material: 10 g/m²) wasproduced in the same manner as in Example 3 except that no shearingdeformation in an in-plane direction was given.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 2.6 N, and the maximum value (average of the threepieces) of load provided till the tensile strain reached 5% was 3.5 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, on the surface of the layeredproduct deformed, many displacements in the weave texture of thereinforced woven fabric were observed, a lot of wrinkles occurredparticularly in the part of a large three-dimensional deformation, andit was not deformed in the same shape as that of the shaping mold. Onthe other hand, no interlayer of the layered product was peeled, and nodeformation occurred in picking the edge to lift. Namely, the preformobtained by this method was excellent in the point of retention of theshape, but a lot of wrinkles occurred on the surface and the shape alongthe shaping mold was not exhibited, so that it was not suitable for useas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wasspread across almost overall and cured, but in the thickened part of thelayered product due to wrinkles, the resin was not sufficientlyimpregnated, and reinforcing fiber bundles were exposed outwards.Further, the resin layer partially became thick in the periphery, beingaccompanied with which, the surface came to be not smooth. Further, inthe weave texture of the reinforcing woven fabric which appeared on thesurface, there was large displacement. Namely, the fiber reinforcedplastic molded component obtained was not suitable for use.

Comparative Example 4

A reinforced woven fabric (stuck amount of resin material: 5 g/m²) wasproduced in the same manner as in Example 4 except that no shearingdeformation in an in-plane direction was given.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 0.90 N, and the maximum value (average of thethree pieces) of load provided till the tensile strain reached 5% was1.2 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, on the surface of the layeredproduct deformed, many displacements in the weave texture of thereinforced woven fabric were observed, a lot of wrinkles occurredparticularly in the part of a large three-dimensional deformation, andit was not deformed in the same shape as that of the shaping mold. Onthe other hand, no interlayer of the layered product was peeled, and nodeformation occurred in picking the edge to lift. Namely, the preformobtained by this method was excellent in the point of retention of theshape, but a lot of wrinkles occurred on the surface and the shape alongthe shaping mold was not exhibited, so that it was not suitable for useas a preform for a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, the resin wasspread across almost overall and cured, but in the thickened part of thelayered product due to wrinkles, the resin was not sufficientlyimpregnated, and reinforcing fiber bundles were exposed outwards.Further, the resin layer partially became thick in the periphery, beingaccompanied with which, the surface came to be not smooth. Further, inthe weave texture of the reinforcing woven fabric which appeared on thesurface, there was large displacement. Namely, the fiber reinforcedplastic molded component obtained was not suitable for use.

Comparative Example 5

A non fiber axis tensile test was carried out for the same bidirectionalfabric substrate as in Example 1 without sticking a resin material andgiving any shearing deformation in an in-plane direction in the same wayas in Example 1. As a result, the maximum value (average of the threepieces) of load provided till the tensile strain reached 1% was 0.22 N,and the maximum value (average of the three pieces) of load providedtill the tensile strain reached 5% was 0.45 N.

This fabric substrate was laid up in the same way as in Example 1, andthe layered product was deformed in the same way using the same shapingmold as in Example 1. Additionally, direction in laying up is notconcerned because no resin material is stuck on this fabric substrate.

When the facing shaping molds were demolded, the layered product wasdeformed in a shape along the shape of the shaping mold. The layeredproduct cooled by cold blast was taken out from the shaping mold, butthe interlayer of the layered product was not bonded at all, the shapeof layered product was collapsed and the shape along the shaping moldwas not able to be retained at all.

In this method, although a fabric substrate was deformed in athree-dimensional shape, the shape was not able to be retained becauseof no adhesion of the interlayer, so that it was not suitable for use asa preform for a fiber reinforced plastic molded component.

Comparative Example 6

A reinforcing woven fabric on that surface resin particles stuck wasproduced in the same manner as in Example 1 except that the amount ofresin material stuck on the surface of a bidirectional fabric substratewas 60 g/m², and the same deformation history as in Example 1 was giventhereto. The surface of the reinforcing woven fabric obtained wasobserved to find that there were a lot of adjacent dotted forms of resinmaterial bonded together, and the surface of the fabric substrate waswidely covered with the resin material. Further, there was no peeling ofthe resin material from the fabric substrate due to giving a shearingdeformation.

A non fiber axis tensile test was carried out for this reinforcing wovenfabric in the same manner as in Example 1. As a result, the maximumvalue (average of the three pieces) of load provided till the tensilestrain reached 1% was 1.3 N, and the maximum value (average of the threepieces) of load provided till the tensile strain reached 5% was 2.1 N.

This reinforcing woven fabric was laid up in the same way as in Example1, and the layered product was deformed in the same way using the sameshaping mold as in Example 1. As a result, on the surface of the layeredproduct deformed, many displacements in the weave texture of thereinforced woven fabric were observed, a lot of wrinkles occurredparticularly in the part of a large three-dimensional deformation, andit was not deformed in the same shape as that of the shaping mold. Nointerlayer of the layered product was peeled, and no deformationoccurred in picking the edge to lift. Namely, the preform obtained bythis method was excellent in the point of retention of the shape, but alot of wrinkles occurred on the surface and the shape along the shapingmold was not exhibited, so that it was not suitable for use as a preformfor a fiber reinforced plastic molded component.

Then, a resin was impregnated in this preform and cured in the same wayas in Example 1 to obtain a fiber reinforced plastic molded component.In the fiber reinforced plastic molded component obtained, although theresin was partially impregnated and cured, there are many parts wherethe resin was not got across and reinforcing fiber bundles were exposedoutwards, so that it was not suitable for use as a fiber reinforcedplastic molded component.

INDUSTRIAL APPLICABILITY

By using the reinforcing woven fabric, it is possible to shapeefficiently and well even in a member having a three-dimensional shape,as a result, it becomes possible to improve the productivity andappearance quality of a fiber reinforced plastic molded component.Therefore, it can be applied widely in the fields of automobile,airplane, marine vessel, home electric appliance, office automationequipment, building material and the like. As a matter of course, theapplication is not limited thereto.

1. A process for producing a reinforcing woven fabric comprising:sticking a resin material on at least one surface of a fabric substratecomprising a plurality of reinforcing fiber bundles; and varying therelative position of the plurality of reinforcing fiber bundles andpeeling the resin material stuck over two or more reinforcing fiberbundles from a part of the two or more reinforcing fiber bundles.
 2. Theprocess according to claim 1, wherein, by giving the fabric substrate ashearing deformation of 5 to 45°, the relative position of a pluralityof reinforcing fiber bundles is varied.
 3. A process for producing apreform comprising: laying up the reinforcing woven fabric according toclaim 1 and a fabric substrate containing reinforcing fiber bundles intoa shaping mold to form a layered product; and pressurizing and heatingthe layered product to soften the resin material stuck on thereinforcing woven fabric and bond an interlayer of the layered product.4. A process for producing a preform comprising: laying up thereinforcing woven fabric according to claim 1 into a shaping mold toform a layered product; and pressurizing and heating the layered productto soften the resin material stuck on the reinforcing woven fabric andbond an interlayer of the layered product.
 5. The process according toclaim 3, comprising: positioning the layered product between at leasttwo facing shaping molds; pressurizing a part of the layered product;and pressurizing and heating a remaining part.
 6. The process accordingto claim 4, comprising: positioning the layered product between at leasttwo facing shaping molds; pressurizing a part of the layered product;and pressurizing and heating a remaining part.
 7. The process accordingto claim 3, comprising: pressurizing a part of the layered product laidup on a shaping mold; covering a sheet on the layered product; andpressurizing and heating the layered product via the sheet by gas or,liquid.
 8. The process according to claim 4, comprising: pressurizing apart of the layered product laid up on a shaping mold; covering a sheeton the layered product; and pressurizing and heating the layered productvia the sheet by gas or liquid.
 9. A process for producing a fiberreinforced plastic molded component comprising: impregnating a matrixresin into a preform produced by the process of claim 3; and curing orsolidifying the preform.
 10. A process for producing a fiber reinforcedplastic molded component comprising: impregnating a matrix resin into apreform produced by the process of claim 6; and curing or solidifyingthe preform.
 11. The process according to claim 1, wherein the resinmaterial sticks more strongly to some fiber bundles compared to otherfiber bundles and varying the relative position of the plurality offiber bundles causes the resin material to peel from the other bundles.